Good evening, im wondering if anyone has gone away with their dual tank set up and what have they done. I currently drive a 96 f250 7.5l sssb and replacing the fuel pumps as been a nightmare. Constantly having defected ones that go out either 50 miles or 100 miles in. Finally the rear tank seem to had luck out but as for the front im still facing the same problem. Delphi is what ive been going with since motorcraft and bosch seem to be nonexistent. I rather stop having to warranty the defected pump and just go through a much simpler set up. I understand there is a bronco conversion. That being said I'd probably have to extend the rear pump that way it sits at the bottom. Any tips on that? Thanks for reading.

 

Well, the pumps have the same design
So a Bronco tank and pump will be the same issue except for the one way valve problem filling the wrong tank
That particular problem will be solved using just one tank
Most people just operate off one tank or the other when they get frustrated by troubles like yours
You can simply block off the lines to the tank not being used anymore
Personally, I'd find factory recall one way valves for big money and fix it that way
That's how I fix all mine (still)
Those one way valves are out there

 

When you say they keep going out, does the whole pump stop working or is it the backflow issue? If the whole pump dies, I would start inspecting all the wires and cleaning grounds. If you’ve already done that, press forward!

 

So initially back pump had a hesistation problem when accerlating hard and that was fixed 2 pumps later but now im going through it when the front. I'm still able to use it i just cant go with the flow of traffic at the same rate as everyone else. I would probably start looking into the bronco set up

 

It has been the pressure reading at the rail
when it’s doing that?

 

The Bronco does not have two tanks so the fuel pump assembly is not the same. Similar, but not the same.

I recently swapped my stock 18gal tank to the 38 gallon version. I purchased the tank conversion and a new pump assembly. I spent a bunch of time making the stock pump work the new tank. I also swapped the new fuel pump with a 340lph pump [I've got a supercharged 351w]. I had an extra front pump assembly so I took the float arm off that assembly and bent it so the float travel was more realistic. The stock rear float arm is way too small. I am certain if you can find some stainless tig welding wire, you can make up something. I silver brazed the longer tubes and angled the lines so the pump sits in a good area. I also made a support arm to keep the assembly from stressing the extended fuel lines.

Once I butchered this complete assembly, I swapped the tank in a couple hours. No real issues. Doing it this way allows you to make all the modification and still drive your car. It took me several days to do what I wanted.

Ford has the worst fuel line quick connects so make certain you have the tools to take the lines off and bring patience. I spent more time screwing with them than the entire job. I ended up cutting the steel line and using a high pressure fuel hose as a 'butt connector'. Yeah, a terrible idea, but it's better than what Ford did.

 

I changed my rear pump and fuel filter recently. The fuel lines were the only part of the project that gave me trouble. I bought metal and plastic quick-disconnects. For whatever reason, the plastic were the only ones I could get to work.

 

I used metal ones. It certainly could have been the tool.

I found that Dorman makes new springs to fit inside the lines. Sadly, they were like most Dorman products, junk. I spent 3 hours driving around to find them and was livid when they just did not work.

 

Changing to the Bronco 33-gallon tank in place of the stock 18-gallon rear tank is a great conversion - BUT it might not work if you have a Class V trailer hitch, and you'll also lose the place for the undermounted spare tire.

 

Yes, the spare tire will not fit the stock location. I swear there is enough room to make it fit below the tank, but my guess is that you will bottom out at some point. I am still trying to figure out a good spot. I don't like it in the bed, but that is where it is at the present time.

I have yet to install a hitch and mine is not a class 5, but the hitch I have will fit. I don't want to guess, but I swear it's a class 3 or 4. I have drilled holes in the frame and test fit it and it does work. I took it out to paint it, once it's done, I will install it.

 

last I checked it was sitting at 28psi and would not raise when regulator hose was pulled up, that was the number for the first failed pump and assuming the rest are the same since they are sharing the same symptoms. I'm not experiencing fuel dumping from the rear to the front again with this new pump. Yeah over this dual tank.

 

Yeah i got the disconnect tool since ive had to do this job at least 5 times already. Good to know regarding that pump your using. Did you find a bronco assembly and swap the pump or did you find a kit to extend your stock pump. Also my truck didnt come with a spare tire but I do have skid plates, did you use the stock skid plates?
thanks

 

I haven't had any issues out of the dual tank setup on my '96 yet, but as soon as I do I plan on going to one 38 gallon rear tank and removing the front tank. I keep reading threads about replacement pumps going bad shortly after installed and it sounds like a nightmare. Could a guy go with an aftermarket frame mounted pump like an old Holley style fuel pump instead of the intake pump? Seems like it would be simpler if it would work. It seems most parts for older rigs are junk now days.